System for correcting misalignment of wood studded building structural parts

ABSTRACT

A prepackaged arrangement of shims for correcting for misalignment of building structural parts, for example, wall studs used in building construction, comprising a plurality of shims provided together in a package, wherein the shims have a length, width and thickness, the shims including at least one shim of a uniform thickness from end to end and at least one shim having a thickness varying from a first thickness at one end to a second thickness at a second end. A method of correcting for the building structural part misalignment is also disclosed.

CROSS REFERENCE TO RELATED APPLICATIONS

This application claims the benefit and priority of U.S. Provisional application Ser. No. 60/516,203 filed Oct. 31, 2003 entitled SYSTEM FOR CORRECTING MISALIGNMENT OF WOOD STUDDED BUILDING WALLS, the entire disclosure of which is incorporated by reference herein.

BACKGROUND OF THE INVENTION

The present invention relates to a system for correcting for misalignment of building structural parts, for example, wood studded building walls. When conventional “stick” construction is used in erecting a building, for example, a residential structure such as a house, ordinarily 2×4s are used as the studs for walls.

Sometimes these studs are misaligned or the boards may be warped. When the drywall is put up, it is necessary to correct for the misalignment in order to achieve substantially even, plumb walls. Shims are employed to do this. The shims are placed along the length of the 2×4 or part of the length, where necessary, to ensure that the studs all project out the same distance so that the drywall will be even and plumb. In the past, the shims are typically made on location or boards can be pre-purchased for making shims.

Applicant is aware of the following prior art:

-   -   Earhart et al., U.S. Pat. No. 5,953,862, Sep. 21, 1999;     -   Foss, U.S. Pat. No. 5,054,250 Oct. 8, 1991;     -   Walper, U.S. Pat. No. 2,041,800 May 26, 1936;     -   Gamba, U.S. Pat. No. 5,163,255, Nov. 17, 1992;     -   Urbain, U.S. Pat. No. 2,239,433, Apr. 22, 1941;     -   Elderson, U.S. Pat. No. 6,021,618, Feb. 8, 2000;     -   Hieger, U.S. Pat. No. 4,558,548, Dec. 17, 1985; and     -   Bogle, U.S. Pat. No. 4,625,489 Dec. 2, 1986.

It is desirable to provide the building trade with a simple and convenient means to correct the misalignment of building structural parts.

SUMMARY OF THE INVENTION

According to one aspect, the invention comprises a prepackaged arrangement of shims for correcting misalignment of building structural parts used in building construction, comprising a plurality of shims provided together in a package, wherein the shims have a length, width and thickness, the shims including at least one shim of a uniform thickness from end to end and at least one shim having a thickness varying from a first thickness at one end to a second thickness at a second end.

According to another aspect, the invention comprises a method for correcting misalignment of building structural parts used in building construction comprising: obtaining a plurality of shims provided together in a package, wherein the shims have a length, width and thickness, the shims including at least one shim of a uniform thickness from end to end and at least one shim having a thickness varying from a first thickness at one end to a second thickness at a second end, and applying at least one of the shims to a building structural part to correct for misalignment of structural part with respect to at least one other structural part.

According to one embodiment, the invention comprises a system of shims that are packaged in prearranged thicknesses, some of them being of a uniform thickness, for example, {fraction (1/16)}th of an inch and others tapering, for example from approximately 0 inches to {fraction (1/16)}th of an inch. Each of the shims preferably will have a width equal to the smaller thickness of a 2×4, that is, approximately 1½ inches thick and 8 feet long, which is the conventional length of a stud 2×4 for wall studding. The invention can be employed also for longer stud lengths, e.g., 10 foot lengths, 12 foot lengths, etc., (and also could be used for 2×6 framing). The package of shims will include a number of shims both of a uniform thickness and tapering, for example, uniform shims of {fraction (1/16)}th inch, {fraction (1/8)} inch, {fraction (1/4)} inch and ½ inch and tapering shims between approximately 0 and {fraction (1/16)}th inch, 0 and {fraction (1/8)} inch, 0 and {fraction (1/4)} inch and 0 and ½ inch, for example, and without limitation. Other thicknesses or measurements can be used, and the measurement system need not be English. For example, metric measurements or increments could be employed.

In addition, the shims can be packaged with string or cord necessary to determine if a wall is even as well as with uniform thickness blocks of several different thicknesses which can be placed on the studs to determine how far misaligned a particular stud of the wall is by comparison to the stretched string or cord. In this way, the user measures between the string which would be arranged horizontally across the studs and the particular stud to determine what thickness of shim to use.

The shims can be packaged as a kit of shims of varying sizes, preferbably with a clear plastic film wrap.

The invention can be used in new construction or during renovation of existing structures.

Although the invention is described herein for use in compensating for wall stud misalignment, the invention can also be used to compensate for misalignment of other building structural parts, for example, floor and ceilings, etc.

BRIEF DESCRIPTION OF THE DRAWINGS

The invention will now be described in greater detail in the following detailed description with reference to the drawings, in which:

FIG. 1 shows an exemplary arrangement of shims of uniform and varying thickness which can be packaged in a pre-packaged kit of shims;

FIG. 2 shows an example of how the shims can be packaged, for example in a plastic film wrapped package for sale; and

FIG. 3 shows a studded wall over which strings have been extended to determine stud misalignment and showing the use of shim gauging blocks.

DETAILED DESCRIPTION

With reference now to the drawings, FIG. 1 shows an example of a system of shims according to the invention. A number of each shim type as shown in FIG. 1 can be provided in a kit or package, for example, ten or one hundred or any desired number of each of the shims shown. In FIG. 1, the first shim is a uniform {fraction (1/16)}th inch in thickness and preferably has the width of a 2×4, that is, approximately 1½ inches.

The second shim tapers from approximately 0 inches to {fraction (1/16)}th inch. The next shim is an even {fraction (1/8)} inch, the next shim tapers from approximately 0 inches to {fraction (1/8)} inch, the next shim is a {fraction (1/4)} inch even, the next shim tapers from approximately 0 inches to {fraction (1/4)} inches, etc. Each of the shims is of equal length, e.g., 8 ft long, but can be provided in different lengths.

Other thicknesses can be provided, for example, {fraction (3/8)} inch, and the dimensions need not be in English measurements, but may be in a metric measurement or any other measurement system. Also, shims can be combined to provide a shim size not in the package. For example, if a shim having a size of {fraction (3/8)} inch is needed and is not in the package, a shim of {fraction (1/4)} inch and a shim of {fraction (1/8)} inch can be combined. If a shim varying in thickness from {fraction (1/8)} inch to {fraction (3/8)} inch is needed, a shim of a uniform {fraction (1/8)} inch and a tapering shim of 0 to {fraction (1/4)} inch can be combined. Alternatively, two tapering shims can be combined. For example, if a shim of 0 to {fraction (3/8)} inch is needed, a tapering shim of 0 to {fraction (1/8)} inch and a tapering shim of 0 to {fraction (1/4)} inch can be combined. Also, the tapering shims need not taper to a point of exactly 0 inch, but may have a defined starting thickness of some defined amount, for example, the shim can taper from {fraction (1/16)} inch to {fraction (1/8)} inch, for example. Also, by 0 inch herein is simply meant that the shim at the 0 inch end has a very small thickness.

FIG. 3 shows a plan view of a number of studs comprising 2×4s in a wall.

Strings can be placed horizontally across the 2×4s to determine which ones are out of alignment. Blocks 10 can be fixed to the end studs to space the string away from all 2×4s in the event the end studs with the blocks are themselves out of alignment. A measurement can be taken between the string and a movable block 10A to determine the misalignment, thereby accounting for the thickness of the block to determine the appropriate shim size. If no gap is observed between the string and moveable block 10A, the fixed alignment blocks 10 have to be increased in thickness. The strings may be disposed as shown at several height locations along the length of the studs to determine the amount of misalignment at various heights of the studs. Suitable shims from the kit of the invention can then be attached to the studs along the entire or partial length of the stud by appropriate fasteners, nails or screws, for example, to correct for the misalignment.

Although the present invention has been described in relation to particular embodiments thereof, many other variations and modifications and other uses will become apparent to those skilled in the art. Therefore, the present invention should be limited not by the specific disclosure herein, but only by the appended claims. 

1. A prepackaged arrangement of shims for correcting misalignment of building structural parts used in building construction, comprising: a plurality of shims provided together in a package, wherein the shims have a length, width and thickness, the shims including at least one shim of a uniform thickness from end to end and at least one shim having a thickness varying from a first thickness at one end to a second thickness at a second end.
 2. The arrangement of claim 1, wherein the building structural parts are wall studs.
 3. The arrangement of claim 1, wherein the shims comprise a plurality of shims of uniform thickness and a plurality of shims of varying thickness.
 4. The arrangement of claim 3, wherein the plurality of shims of varying thickness are provided in a plurality of varying thickness sizes.
 5. The arrangement of claim 4, wherein the plurality of shims of varying thickness comprises a plurality of tapering shims, with at least one shim tapering from a first thickness to a second thickness, and at least one shim tapering from the second thickness to a third thickness.
 6. The arrangement of claim 5, wherein the shims of varying thickness are provided such that the thickness between shims vary in increments of {fraction (1/16)} inch from shim to shim at respective ends of each shim.
 7. The arrangement of claim 6, wherein the shims of varying thickness cover a range from approximately 0 to {fraction (1/16)} inch, approximately 0 to {fraction (1/8)} inch, approximately 0 to {fraction (1/4)} inch and approximately 0 to 12 inch.
 8. The arrangement of claim 3, wherein the plurality of shims of uniform thickness are provided in a plurality of uniform thickness sizes.
 9. The arrangement of claim 3, wherein the shims of uniform thickness have thicknesses of {fraction (1/16)} inch, {fraction (1/8)} inch, {fraction (1/4)} inch and {fraction (1/2)} inch.
 10. The arrangement of claim 1, wherein the package is wrapped in a plastic wrap.
 11. The arrangement of claim 10, wherein the plastic wrap is clear.
 12. The arrangement of claim 1, further comprising at least one gauge block in the package.
 13. The arrangement of claim 1, further comprising at least one string or cord for gauging building structural part misalignment in the package.
 14. The arrangement of claim 1, wherein the width of the shims is greater then the thickness.
 15. A method for correcting misalignment of building structural parts used in building construction, comprising: obtaining a plurality of shims provided together in a package, wherein the shims have a length, width and thickness, the shims including at least one shim of a uniform thickness from end to end and at least one shim having a thickness varying from a first thickness at one end to a second thickness at a second end; and applying at least one of the shims to a building structural part to correct for building structural part misalignment with respect to at least one other building structural part.
 16. The method of claim 15, wherein the step of obtaining comprises obtaining shims comprising a plurality of shims of uniform thickness and a plurality of shims of varying thickness.
 17. The method of claim 16, wherein the step of obtaining comprises obtaining a plurality of shims of varying thickness in a plurality of varying thickness sizes.
 18. The method of claim 17, wherein the step of obtaining comprises obtaining a plurality of shims of varying thickness comprising a plurality of tapering shims, with at least one shim tapering from a first thickness to a second thickness, and at least one shim tapering from the second thickness to a third thickness.
 19. The method of claim 18, wherein the step of obtaining comprises obtaining a plurality of shims of varying thickness such that the thickness between shims vary in increments of {fraction (1/16)} inch from shim to shim at respective ends of each shim.
 20. The method of claim 19, wherein the step of obtaining comprises obtaining a plurality of shims of varying thickness covering a range from approximately 0 to {fraction (1/16)} inch, approximately 0 to {fraction (1/8)} inch, approximately 0 to {fraction (1/4)} inch and approximately 0 to {fraction (1/2)} inch.
 21. The method of claim 16, wherein the step of obtaining comprises obtaining a plurality of shims of uniform thickness provided in a plurality of uniform thickness sizes.
 22. The method of claim 15, wherein the step of obtaining comprises obtaining a plurality of shims of uniform thicknesses having thicknesses of {fraction (1/16)} inch, {fraction (1/8)} inch, {fraction (1/4)} inch and ½ inch.
 23. The method of claim 15, wherein the step of obtaining comprises obtaining a package wrapped in a plastic wrap.
 24. The method of claim 23, wherein the plastic wrap is clear.
 25. The method of claim 15, further comprising providing at least one gauge block in the package.
 26. The method of claim 15, further comprising providing at least one string or cord for gauging building structural part misalignment in the package.
 27. The method of claim 15, wherein the width of the shims is greater than the thickness. 